Support surface and method of consruction thereof

ABSTRACT

A support surface, comprising a first, substantially planar rigid surface connected to a second substantially hemispherical, substantially non-rigid portion, wherein the support surface is arranged to be positionable in at least two orientations, wherein at least one orientation provides a substantially planar support surface, and at least one other orientation provides a seating surface.

This application claims benefit of U.S. Provisional Application Ser. No. 62/541,255 filed Aug. 4, 2017, and claims priority to Australian patent application no. 2017265082 filed Nov. 22, 2017, both of which are incorporated by reference herein in their entirety.

TECHNICAL FIELD OF INVENTION

The present invention relates to a support surface and a method of constructing the support surface. In one embodiment, the invention relates to a seating surface and a method of constructing the seating surface. In a more particular embodiment, the invention relates to a method of manufacturing a curved seating surface and a method of construction of the curved seating surface.

BACKGROUND

In the context of the specification, the term “support surface” encompasses a piece of furniture for use by a person and capable of “supporting” one or more objects. In other words, a “support surface” includes furniture items such as a table, but equally encompasses furniture items such as a chair or a cupboard. In other words, the terms “support surface” should be construed broadly, as defined above.

Support surfaces are available in a number of shapes and sizes and can be provided in any one of a number of different sizes, configurations and materials. In some instances, support surfaces are manufactured such that they may have multiple uses.

For example, there is a known furniture item that functions as either a table or a chair. This item requires a wooden surface to be rotated at a pivot point about a metal frame. To convert the table to a chair (or vice versa) requires a certain amount of skill and knowledge. It is therefore not suitable for use by children, who may injure themselves when trying to convert the table to a chair (or vice versa).

Moreover, such chairs are not padded (due to the fact that the seating surface and the table surface are one and the same), which makes such chairs less comfortable.

It is with these issues in mind that the present invention has been developed.

SUMMARY OF THE INVENTION

In a first aspect, there is provided a support surface, comprising a first, substantially circular, substantially planar rigid surface having a plurality of support elements, the first surface being connected to a second substantially hemispherical, substantially non-rigid portion having at least two sections proximate each other, each one of the at least two sections cooperating with a proximate section to control the amount of cushioning provided by the surface, wherein the support surface is arranged to be positionable in at least two orientations, wherein at least one orientation provides a substantially planar support surface, and at least one other orientation provides a seating surface.

In one embodiment, the at least two sections are one of hemispherical wedges and planar slices.

In one embodiment, the at least two sections are composed of a compressible solid foam material.

In one embodiment, the non-rigid portion includes at least one cavity.

In one embodiment, the non-rigid portion further includes a surface material.

In one embodiment, the surface material includes a pattern including two or more gores integrally formed at the apex of the support surface.

In a second aspect, there is provided a support surface, comprising a first, substantially planar rigid surface connected to a second substantially hemispherical, substantially non-rigid portion, wherein the support surface is arranged to be positionable in at least two orientations, wherein at least one orientation provides a substantially planar support surface, and at least one other orientation provides a seating surface.

In one embodiment, the substantially hemi-spherical non-rigid portion further comprises at least two sections proximate each other, wherein each section cooperates with a proximate section to control the amount of cushioning provided by the surface.

In one embodiment, the at least two sections are hemispherical wedges.

In one embodiment, the at least two sections are planar slices.

In one embodiment, the at least two sections comprises twelve wedges, to form a shape that approximates a hemisphere.

In one embodiment, the substantially planar rigid surface is substantially circular.

In one embodiment, the substantially planar rigid surface includes a plurality of support elements.

In one embodiment, the non-rigid portion comprises a compressible solid foam material.

In one embodiment, the foam material is a polyurethane foam.

In one embodiment, the non-rigid portion includes at least one cavity.

In one embodiment, the non-rigid portion further includes a surface covering material.

In one embodiment, the surface covering material is textured.

In one embodiment, the surface material includes a pattern including two or more gores integrally formed at the apex of the support surface.

In one embodiment, the surface material is one of a woven material, a vinyl or plastics material and a surface of synthetic fibres.

In a third aspect, there is provided a method of constructing a support surface, comprising the steps of shaping and attaching one or more sections of solid foam material into a substantially hemispherical portion, attaching the substantially hemispherical portion to a substantially rigid surface, and attaching a surface material that substantially covers the hemispherical portion.

In one embodiment, the step of shaping the one or more sections of solid foam comprises the step of shaping at least two hemispherical wedges.

In one embodiment, the step of shaping the one or more sections of foam comprises the step of shaping at least two spherical slices.

In one embodiment, the step of attaching one or more sections of foam material comprises the step of chemically bonding the one or more sections.

In one embodiment, the step of attaching the hemispherical portion to the rigid portion comprises the step of chemically bonding the hemispherical portion to the rigid portion.

In one embodiment, the step of attaching the surface material to the hemispherical portion comprises the step of chemically bonding the surface material to the hemispherical portion.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features of the present invention are more fully described in the following description of several non-limiting embodiments thereof. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which:

FIG. 1 is an exploded view of a support surface in accordance with a first embodiment of the invention;

FIG. 2 is a side view of a support surface in accordance with the first embodiment of the invention;

FIG. 3 is a top view of a support surface in accordance with the first embodiment of the invention;

FIG. 4 is a perspective view of a support surface in accordance with a second embodiment of the invention;

FIG. 5 is a top view of a support surface in accordance with the second embodiment of the invention;

FIG. 6 is a side view of a support surface in accordance with the second embodiment of the invention;

FIG. 7 is an exploded view of a support surface in accordance with the second embodiment of the invention;

FIG. 8 is an exploded view of a support surface in accordance with the second embodiment of the invention;

FIG. 9A is a cut away view of a support surface in accordance with the first embodiment of the invention;

FIG. 9B is a cut away view of a support surface in accordance with the second embodiment of the invention;

FIG. 9C is a perspective view of a support surface in accordance with an embodiment of the invention;

FIG. 9D is a top view of a support surface in accordance with an embodiment of the invention; and

FIG. 9E is a top view of a support surface in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In the following detailed description of FIGS. 1 to 9, like numerals across different Figures refer to like features and/or integers.

The present invention relates generally to a support surface 100, comprising a first, substantially planar rigid surface 102 connected to a second substantially hemispherical, substantially non-rigid portion 104, wherein the support surface is arranged to be positionable in at least two orientations, wherein at least one orientation provides a substantially planar support surface, and at least one other orientation provides a seating surface.

The substantially hemi-spherical non-rigid portion 104 further comprises at least two sections (all labelled 106) proximate each other, wherein each section 106 cooperates with a proximate section 106 to control the amount of cushioning provided by the surface.

As can be seen in FIGS. 1 to 3, the at least two sections are hemispherical wedges, although in an alternative embodiment, as shown in FIGS. 4 to 7, the at least two sections may be planar slices, such as the planar slices denoted by numeral 706 in FIG. 7.

While the non-rigid portion 104 shape as a whole is referred to as a hemisphere, for ease of reference, in one embodiment, the portion 104 is composed of twelve wedges, which form a dodecahedron shape, such that the dodecahedron shape approximates a hemisphere.

As can be seen from both the first and second embodiments, the substantially planar rigid surface 102 is substantially circular in shape and can optionally (not shown in the embodiments) include a plurality of support elements. The support elements are essentially “feet” which provide additional stability to the support surface. The substantially planar rigid surface 102 may be comprised of plywood, plastic, metal or other such rigid materials or a combination of such materials within the workings of the present invention.

The non-rigid surface and/or surface segments is composed of a compressible solid foam material, such as but not limited to a polyurethane foam. The foam material may be varied or modified to also include materials that include additional advantageous features, such as fire-retardant, non-toxic or non-irritant materials.

As shown in FIG. 8, an embodiment of the support surface 800 includes a section 806 of the non-rigid portion 804 includes at least one cavity 808, which allows the support surface to also act as a storage space. In this embodiment, the cavity 802 is accessed by means of a channel 810.

The non-rigid portion is generally covered with a surface material, which may be textured. The surface material may be a woven material, a vinyl or plastics material and an artificial surface of synthetic fibres, such as an artificial “turf” material. The surface material may consist of a single piece of material or a number of connected sections of material. The sections of material may be connected in a pattern for visual appeal and/or structural support.

Referring to FIGS. 9A and 9B, the surface material 902 in the first embodiment 900 is shown to provide a “parachute” pattern including multiple gores 904. Although the surface material 908 of the second embodiment 906 also illustrates the same pattern with gores 910, alternative patterns may be used, such as but not limited to, a geodesic pattern (not shown).

Alternatively, as shown in FIGS. 9C, 9D, and 9E, the gores may be integrally formed from a single piece of material. Referring to FIG. 9C, an embodiment 914 is provided where multiple gores are provided by a single pattern or piece of material, where one or more patterns or pieces of material may be used to form the surface material. This pattern would include two or more gores being integrally connected at the apex of the support surface.

As shown in FIG. 9D, the embodiment 916 includes gores joined along part of their length to provide a snug fit around the exterior of the support surface. In the Figures provided, a single pattern for the entire support surface is shown. However, it is well within the purview of the skilled addressee that one or more patterns may be used where each pattern may have two or more integrally formed gore portions to allow for easier manufacturing of the pattern and assembly of the support structure.

As shown in FIG. 9E, an example of integrally formed surface material pattern 918 is provided, where the gore portions of the pattern are joined towards the middle of the pattern which aligns with the apex of the support structure. When affixing the surface material to the support surface, the “legs” of the gore portions are joined to one another along their edges by either sewing or stitching together the edges of the gores, binding the edges of the gores with a suitable adhesive, chemical bonding, heat fusing or a combination of methods.

Referring again to FIG. 9B, the non-rigid portion may also be covered with an “underlay” padding material 912 in FIG. 9B, which sits underneath the surface material 908. The use of padding material 912 or the use of a relatively thick surface material 908 may serve to make the non-rigid portion more hemispherical in shape, by constraining the wedges or disks into a shape that better approximates a hemispherical shape. The padding material may consist of a material made from Polyethylene terephthalate, such as polyester fibre material known as “Dacron”, or materials made from natural fibre, such as wool or bamboo alternatives, or any other material that provides a soft padding.

Additionally, the padding material 912 may be varied or modified to also include materials that include additional aspects, such as fire-retardant, non-toxic or non-irritant materials.

The support surface is constructed, in one embodiment, by firstly shaping and attaching one or more sections of solid foam material into a substantially hemispherical portion, attaching the substantially hemispherical portion to a substantially rigid portion, and attaching a surface material that substantially covers the hemispherical portion.

The step of shaping the one or more sections of solid foam may be performed by shaping at least two hemispherical wedges or shaping at least two spherical slices.

Each step of attaching one or more sections of foam material together may be achieved by chemically bonding the one of more sections, by using a glue, a heating technique, or any other suitable catalyst to promote a chemical bonding.

Similarly, the step of attaching the hemispherical portion to the rigid portions may also be achieved by chemical bonding the hemispherical portion to the rigid portion.

Likewise, the step of attaching the surface material and/or the padding material to the hemispherical portion can also be achieved by chemical bonding the surface material to the hemispherical portion. Alternatively, the step of attaching the surface material and/or the padding material to the hemispherical portion can be achieved by stapling the material to one or more locations on the underside of the substantially planar rigid surface. In an alternative embodiment, different means may be used to attach the surface material and/or the padding material to the hemispherical portion. The different means may include one or more of a pin, plug or screw.

Other techniques for forming the non-rigid portion are also contemplated. For example, a liquid foam may be poured into a hemispherical mould and allowed to harden. Such variations are within the purview of a person skilled in the art.

ADVANTAGES

One of the advantages of the embodiments and broader invention described herein is that the support surface is multi-functional, in that the cushioned surface of the support surface functions both as a comfortable seat and also as a support for the base, in the case where in the dome is turned over and used as a table.

Moreover, by making the non-rigid section from sections (whether wedges or slices), the support surface is manufactured easily, but also allows for the use of different density foams throughout the structure, to create a variable cushioning effect that makes for a more comfortable seating experience and a more long-lived product.

In addition, the support surface can be turned from a table to a seating surface (and vice versa) by simply turning the surface from one orientation to another. This makes the conversion incredibly easy and intuitive, meaning that the support surface can be used by adults and children alike, without the need for instruction.

Advantageously, the embodiments described herein have no hinges, catches, or other mechanisms which may serve to cause injuries. The absence of such mechanisms makes the support surface extremely child friendly, as the possibility of a child injuring themselves is reduced compared to known convertible furniture.

Furthermore, the lightweight construction of the support surface makes it easy to move and reduces the risk of a child being trapped or injured when carrying, turning over, or otherwise interacting with the support surface.

Moreover, the use of the surface material where two or more gores are integrally formed at the apex of the support surface advantageously reduces the likelihood of wear and damage to the material at the apex, which undergoes the most wear, fabric displacement and general movement in use. Having the gore internally formed together greatly reduces the risk of tearing stitches, fraying, and/or damaging the surface material of the support surface as the join areas.

Further, providing a pattern without stitches at the apex of the support structure prevents users from forcefully creating finger-holds between the joins in the gores. As such, the use of the support structure is improved by ensuring that it is carried, moved and used safely without causing damage to the structure.

Lastly, in the embodiment including one or more cavities, the cavity may be used to hold objects, making the support surface function as a storage space, in addition to functioning as a table or seating surface.

DISCLAIMERS

Throughout this specification, unless the context requires otherwise, the word “comprise” or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers but not the explicit exclusion of any other integer or group of integers.

Those skilled in the art will appreciate that the embodiments described herein are susceptible to obvious variations and modifications other than those specifically described, and it is intended that the broadest claims cover all such variations and modifications. Those skilled in the art will also understand that the inventive concept that underpins the broadest claims may include any number of the steps, features, and concepts referred to or indicated in the specification, either individually or collectively, and any and all combinations of any two or more of the steps or features may constitute an invention.

Where definitions for selected terms used herein are found within the detailed description of the invention, it is intended that such definitions apply to the claimed invention. However, if not explicitly defined, all scientific and technical terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the invention belongs. 

1. A support surface, comprising a first, substantially circular, substantially planar rigid surface having a plurality of support elements, the first surface being connected to a second substantially hemispherical, substantially non-rigid portion having at least two sections proximate each other, each one of the at least two sections cooperating with a proximate section to control the amount of cushioning provided by the surface, wherein the support surface is arranged to be positionable in at least two orientations, wherein at least one orientation provides a substantially planar support surface, and at least one other orientation provides a seating surface.
 2. A support surface in accordance with claim 1, wherein the at least two sections are one of hemispherical wedges and planar slices.
 3. A support surface in accordance with claim 1, wherein the at least two sections are composed of a compressible solid foam material.
 4. A support surface in accordance with claim 1, wherein the non-rigid portion includes at least one cavity.
 5. A support surface in accordance with claim 1, wherein the non-rigid portion further includes a surface material.
 6. A support surface in accordance with claim 5, wherein the surface material includes a pattern including two or more gores integrally formed at the apex of the support surface.
 7. A support surface, comprising a first, substantially planar rigid surface connected to a second substantially hemispherical, substantially non-rigid portion, wherein the support surface is arranged to be positionable in at least two orientations, wherein at least one orientation provides a substantially planar support surface, and at least one other orientation provides a seating surface.
 8. A support surface in accordance with claim 7, wherein the substantially hemi-spherical non-rigid portion further comprises at least two sections proximate each other, wherein each section cooperates with a proximate section to control the amount of cushioning provided by the surface.
 9. A support surface in accordance with claim 8, wherein the at least two sections are hemispherical wedges.
 10. A support surface in accordance with claim 8, wherein the at least two sections are planar slices.
 11. A support surface in accordance with claim 8, wherein the at least two sections comprises twelve wedges, to form a shape that approximates a hemisphere.
 12. A support surface in accordance with claim 7, wherein the substantially planar rigid surface is substantially circular.
 13. A support surface in accordance with claim 7, wherein the substantially planar rigid surface includes a plurality of support elements.
 14. A support surface in accordance with claim 7, wherein the non-rigid portion comprises a compressible solid foam material.
 15. A support surface in accordance with claim 14, wherein the foam material is a polyurethane foam.
 16. A support surface in accordance with claim 7, wherein the non-rigid portion includes at least one cavity.
 17. A support surface in accordance with claim 7, wherein the non-rigid portion further includes a surface covering material.
 18. A support surface in accordance with claim 17, wherein the surface covering material is textured.
 19. A support surface in accordance with claim 17, wherein the surface material includes a pattern including two or more gores integrally formed at the apex of the support surface.
 20. A support surface in accordance with claim 17, wherein the surface material is one of a woven material, a vinyl or plastics material and a surface of synthetic fibres.
 21. A method of constructing a support surface, comprising the steps of shaping and attaching one or more sections of solid foam material into a substantially hemispherical portion, attaching the substantially hemispherical portion to a substantially rigid surface, and attaching a surface material that substantially covers the hemispherical portion.
 22. A method in accordance with claim 21, wherein the step of shaping the one or more sections of solid foam comprises the step of shaping at least two hemispherical wedges.
 23. A method in accordance with claim 21, wherein the step of shaping the one or more sections of foam comprises the step of shaping at least two spherical slices.
 24. A method in accordance with claim 23, wherein the step of attaching one or more sections of foam material comprises the step of chemically bonding the one or more sections.
 25. A method in accordance with any one of claims 21, wherein the step of attaching the hemispherical portion to the rigid portion comprises the step of chemically bonding the hemispherical portion to the rigid portion.
 26. A method in accordance with any one of claims 21, wherein the step of attaching the surface material to the hemispherical portion comprises the step of chemically bonding the surface material to the hemispherical portion. 